Multipurpose & versatile compound Minerals In Textile Processing

ALTRANOL-GEO/ ALTRANOL-ELB

The textile industry is constantly searching for environmentally friendly solutions.

Over the years a lot of chemical components have been replaced (Phosphates, Nonyl phenols etc) in the textile industry.

The demand for low COD and BOD values, reduced levels of MBAS and BiAS and easily biodegradable products was the reason to search for alternative sources.

Clay Chemistry

Elements of Earth8.32 kms crust

% by weight in crust

O = 49.2Si = 25.7Al = 7.5Fe = 4.7Ca = 3.4Na = 2.6K = 2.4Mg = 1.9other = 2.6

12500 km dia

Geotechnical engineers are interested mainly in the top 100 metres of the earth crust. As you can see from the table, 82% of the elements are oxygen, silicon and aluminium.

Soil Formation

Parent Rock

Residual soil Transported soil~ in situ weathering (by

physical & chemical agents) of parent rock

~ weathered and transported far away

by wind, water and ice.

Genesis of Clays

Parent Rock

~ formed by one of these three different processes

igneous sedimentary metamorphic

formed by cooling of molten magma (lava)

e.g. granite

formed by gradual deposition, and in layers

e.g. limestone, shale

formed by alteration of igneous & sedimentary

rocks by pressure/ temperature

e.g. marble

Mother earth supplies us with a large variety of minerals. Approx. 4000 different minerals are known worldwide, most of them are very

nice but not all of them can be used for technical purposes.

Rosa Quartz Roselite Biotite Kaolinite Rosasite Topaz

99% of the earth is composed out of only 8 minerals. The mineral group of silicates is the most important and well known for:

- Clays (Aluminium/Metal oxides + Silicium dioxide)- Zeolites (Aluminium/Metal oxides + Silicium dioxide)- Silicate (Metal oxides + Silicium dioxide)

Minerals - Introduction Minerals - Introduction

Basic Structural UnitsClay minerals are made of two distinct structural units.

oxygen

0.29 nm

aluminium or magnesium

hydroxyl or oxygen

silicon

0.26 nm

Silicon tetrahedron Aluminium Octahedron

All clay minerals are made of two distinct building blocks: tetrahedrons and octahedrons. The tetrahedron on the left has oxygen atoms at the corners, and there is a silicon in the centre. Octahedron has six oxygen or hydroxyl atoms in the corners, and an aluminium or magnesium ion at the centre.

Mining of Clay

Mining process of Clays

Microscopic Photograph of Clay

Depending on the type and quantity of metal oxide, the ratio withSiO2 and the specific crystalline structure, different types of CLAYare known such as:

- Kaolin : Aluminium oxide- Smectite : Aluminium- and Magnesium oxide- Vermiculite : Aluminium- and Magnesium oxide- Illite : Aluminium-, Magnesium- and

Potassium oxide- Hectorite : Magnesium- and Lithium oxide

CLAY TYPES

• Clay mainly consists of SiO2 and Al2O3

• Other ions may be present Mg, Ca, Fe, Li, Mn,…..• Some clays can stabilize H2O2 bleaches

CLAYS

• 3-Layer Silicate

• Small particle size

• Sheet Structure

• Delaminating of layers by simple dispersing• High specific surface area(upto 750m2/g after dispersed

• Negative charge on the surface, cationic charge at border

• Inner crystalline capability of swelling

Character of Semectite Clays

Isomorphous Substitutionsubstitution of Si4+ and Al3+ by other

lower valence (e.g., Mg2+) cationsresults in charge imbalance (net negative)

++

++ +

+

+

___

__

_

_

__

_

_

_

_

_

_

_

_

_

_

__

__

positively charged edges

negatively charged faces

Clay Particle with Net negative Charge

The clay particle derives its net negative charge from the isomorphous substitution and broken bonds at the boundaries.

A Comparison

Mineral Specific surface(m2/g)

C.E.C (meq/100g)

Kaolinite 10-20 3-10

Illite 80-100 20-30

Montmorillonite 800 80-120

Chlorite 80 20-30

• Amongst the big number of minerals, clays have very useful characteristics for textile applications

Some clay-classifications:• Kaolin (Aluminium: “China clay”)• Semectite (Aluminium + Magnesium)• Hormite (more Iron)

• Some exceptional properties of clay:• Thickening agents in paints• Oil and dirt absorber• Absorber of inks in e.g. paper industry• Stabilizer for hydrogen peroxide bleaches• Softening agents in household products

CLAYS

• In water the clay particles are anionic charged and show a large adsorption effect for:

-Hydrophobic waxes and oils-Metal ions (cation exchange capacity)-Hydrophilic materials and polymers

CLAYS

• Nature –Bentonite• Cat litters• Agro industry• Civil industry• Beverage refinery

industry

Alkaline activation(With soda ash)• Foundry industry• Civil & drilling industry• Detergent, paper, textile

industry• Beverage refinery

industry• Rheological additive

industry

• Acidic activation• (with HCl / H2SO4)• Food industry• Paper industry• Beverage refinery

industry• Industrial catalyst

Organic activation(With organic cation subst)• Pigment & paint industry• Sealing industry• Fat lubricant industry• Cosmetic industry

Application of Clays in Industry

All these classes (and many sub-classes) have different characteristics

Because of this different special industrial applications e.g. paper coating

In the past clays were used by Indian and Egyptian women to clean and smoothen their faces and to shampoo their hair. Clay masks and still popular!

The clay structure is based on sheets By separating these sheets e.g. by stirring, a

very big surface is created This surface (till 800 M2 per gram) makes it

possible to absorb all kind of components like dirt, oil, greases etc.

This gives an unique detergency effect

CLAYS

MineralsThe most widely known mineral in the

textile industry is sodium silicate as a mineral stabilizer for hydrogen peroxide bleaching

L.N.’s challenge: look for other minerals with the good properties of sodium silicate and with success!!

Clay minerals have been selected on the specific characteristics and formulated in new auxiliaries for the textile industry

• NaOH• Gives irreversible yellowing to cotton due to high alkaline• High COD amount in waste water

• Water glass• Salt reaction• Needs to look for effective conventional auxiliaries• Building deposits on the fabric and machineries

• Complex Builder• Ecological problem• Effective depend on the degree of water hardness and

heavy metal contamination on the raw materials

Problems During Bleaching Process

• Adsorption of strong metal contamination

• Organic complex builder fully or partially to be substituted

• Water glass fully or partially to be substituted

An organic Ions Exchanger with capability of

A selection of high quality minerals for excellent

results• In hydrogen peroxide bleaching,

both continuously and discontinuously

• In continuous desizing of synthetics

• In post scouring reactive dyed and printed cellulosics

ALTRANOL-GEO/ ALTRANOL-ELB

• One of the new applications for clays is as a one-shot product for the discontinuous bleaching applications

• It is based on this mineral technology

• A clay based multifunctional auxiliary for the discontinuous bleaching of cotton with hydrogen peroxide on jets, winches and overflows

• Prescouring of PES/EL and PA/EL

• Alternative for the ecologically unfriendly hypochlorite bleach

Without product 2 g/l pure non-ionic

Without product 2 g/l TANNEX GEOWithout product 2 g/l TANNEX GEO

Emulsifying capacity for silicone oil

Clearly to see is that the silicon oil is not well emulsified.

Altranol- GEO well disperse/emulsifies the silicon oil.

2g/l Altranol-GEO

Without product 2 g/l TANNEX GEOWithout product 2 g/l TANNEX GEO

Without product

Excellent hydrogen peroxide stabilizerUnique wash performanceGood wetting out of the fabricExcellent lubrification propertiesLow foaming; no defoamer requiredEcologically very friendlyGives fabric a smooth handle

ALTRANOL-GEO

Altranol GEO allows almost 35% reduction in the BOD & COD levels in the wash effluent

Altranol GEO further reduces the COD/BOD levels by eliminating/reducing the need for additional auxiliaries in treatment baths i.e. wetting agents, chelating agents, surfactants, lubricants & defoamers.

The effluent of treated textiles is easily & readily treated by flocculating, precipitating or filtering the natural clays & its adsorbed/precipitated contaminants, which are removed by any standard separation technique like filtering etc.

The resultant effluent is significantly more environmentally acceptable than current effluents containing organic components & inorganic contaminants.

Why Should One Use Altranol ELB

Altranol ELB, besides reducing pollution due to lower BOD & COD levels, also results in lower volatile organic chemicals (VOC’s)

Is an outstanding lubricating agent providing a softer hand for treated textile goods

Is non-foaming & extremely effective in removing processing oils & excess auxiliaries & other impurities from the substrates. Treated substrates are cleaner which improves dyeability & dye penetration resulting in increased colour yields of 10~30%

Is suitable for processing all textile materials i.e. all fibres, filament, yarns, fabric & all products made from them. They include textured & non textured filaments & yarns, woven, knitted or non-woven fabrics.

Why Should One Use Altranol ELB

Excellent extracting effect to silicone or mineral oils from elastane fibers when blended with cotton / polyamide / polyester

Stabil whiteness degree with possibility of increasing whiteness degree after every bleaching process

Reduction of COD value in waste water

Heavy metals adsorption reduction of potential pin holes problem

Softness effect on cotton fiber anti crease mark effect

Why Should One Use Altranol ELB

Bleach for whites indication recipe: 1-3 ml/l Altranol-GEO 2-3, 5g/l Caustic flakes 6-10 ml/l Hydrogen peroxide 35% X % Optical brightening agent 95-110ºC during 90-30 minutes

Altranol- GEO

• Some practical results:• Cotton on winches 95ºC – 60 mins;• Customer’s standard: LNCI• Basic white : 84 85• Total white : 155 158• S-factor : 0.36 0.32

Altranol- GEO

• Practical results continued:• Knitted Cotton/EL on Thie jet

• Customer’s standard: LNCI• Basic white : 72 77• Total white : 144 156• S-factor : 0.2 0.1

Altranol- GEO

Other experiences: Jig bleaching applications Bleaching of Cotton on X-cones Discontinuous bleaching of Linen Prescour PA/EL Prescour PES/EL Etc…………..

Altranol- GEO

Clay technology for pretreatment of elastane fibres

Altranol- ELB

• Elastane fibres (Polyurethane filament fibres) are commonly used nowadays in all kind of knits and fabrics.

• Elastane fibres provide knits and fabrics stretch and retention effects.

• Elastane fibres are blended with all kind of other fibres like PA, PES, Wo and Co.

Altranol- ELB

• Articles can contain between 2 – 20% elastane fibres.

• Articles can contain between 2 – 6% silicone oils.

• Depending on the fibre blend this silicone oil, in combination with other fibre preparations (mineral oils, waxes, lubricants etc) could cause problems during further processing.

Altranol- ELB

• Insufficient elimination of silicon oils will cause problems during subsequent processes and/or dyeings:

- silicon spots and/or stripes on the material- silicon deposits in the machine

- fumes and yellowing during thermofixation

• Silicone oil on the elastane fibres is absolutely necessary to provide sufficient elasticity and avoid aging.

• What is a safe way of processing elastane fibres ?

Altranol- ELB

• Altranol-ELB is a specially formulated clay in combination with special non – ionic surfactants.

• The clay in Altranol-ELB is from the same origin as in Altranol-GEO

• Altranol-ELB removes all superficial silicone oil, providing level dyeings, without totally removing the silicone oil.

• A certain amount of residual silicone oil is required to guarantee durable elasticity and to avoid ageing of the elastane-fibre.

Altranol- ELB

• Very good wetting and scouring effect.• Level dyeings as Altranol-ELB levels out all irregular

oil contents.• Residual silicone oil to protect the Elastane fibre in

order to maintain durable elasticity and avoid ageing.• Simple to dispense and easy to handle.• Lubrication action due to the presence of clay .• Applicable on all fibre blends with Elastane fibres.• Non foaming.• Ecological product (COD 560 mg O/g, BiAS 210 mg/g)• APEO free.

Altranol- ELB

Soda ash pH 9-10 (1 g/l) Altranol- ELB 2 ml/l + 1 ml/l

water 2-3 l/kg overflow30°C

Grey

water 6-8 l/kg

°C 30 30 80 80 80 60 40

Altranol- ELB Continuous scouring PA/EL fabrics

0

20

40

60

80

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120

0 10 20 30 40 50 60 70 80Time [min]

Te

mp

era

ture

[°C

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15 min @ 50°C Dyeing

Refill and add Altranol-ELB 0.5 ml/lother dyeing auxiliaries dyestuffs

Fill the machine and add

Altranol-ELB 1–2 ml/l

Soda ash 0.5 – 1 g/l

Ratio 10:1

Altranol- ELB Discontinuous pre-scouring

PA/EL & PA/EL KNITS

• Special multipurpose versatile compound for wet processing of textile goods made of natural & synthetic fibres:

Complete, balanced bleaching assistant for single

stage bleaching

Washing elastane blends

Cleaning effects on the machinery

Ecological beaching procedure. Environmentally

friendly

Positive issue on waste water treatment

ALTRANOL-GEO

L.N.Chemical Industries

OFFICE ADDRESS :403, “Antariksh”, Makwana Road,Marol Naka, Andheri (E),Mumbai - 400 059

Tel.- 91-22-4221 6789 (30 Lines) 91-22-6692 4112Fax -91-22-2836 6434

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Email ID: ketan@lnchem.innayana.lnchem@gmail.com